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TISP:
Uruguay
9–10 May 2009
WELCOME!
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TISP:
Uruguay
9–10 May 2009
Christopher Lester
Yvonne Pelham
Moshe Kam
D.G. Gorham
Sort It Out
Critical Load
Pulleys and Force
Ship the Chip
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Welcome
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Exercise 1:
Ship The
Chip
Package design and the
engineering behind
shipping products safely
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5
Ship the Chip
Objectives
 Learn
about engineering product planning
and design
 Learn
about meeting the needs of the
customer and society
 Learn
about teamwork and cooperation
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Ship the Chip
Students will learn…
Manufacturing
 Package
Engineering
design, manufacture
and test
 Material properties and
selection
Real
world application of
mathematics
Teamwork
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Ship the Chip
The Challenge
 Design
a package that will securely hold a
potato chip and protect it from breaking
when dropped
 Construct
the lightest package
to get the highest score
 Overall



score based on:
Weight of the package
Volume of the package
Intactness Score
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Ship the Chip
Procedure
Sketch a design on the worksheet
1.

Label your worksheet with Table # and Team Name
2.
Construct a model of your package
3.
At a test station, drop the package from a height of 1.5 meters
4.
Open your package and examine the chip
5.
Calculate and record your score
6.
Using a second kit, redesign and construct a new package

Record the second design on the worksheet
7.
Label your package with Table # and Team Name
8.
Submit your worksheet and package to the Test Team for
overnight testing
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Ship the Chip
Materials

Cardboard – 22 cm x 28 cm

10 Craft sticks

6 Cotton Balls

String – 91 cm

Plastic wrap – 1 sheet of 22 cm x 28 cm

10 Toothpicks

Foil – 1 sheet of 22 cm x 28 cm

Paper – 1 sheet of 22 cm x 28 cm

1 Mailing label

1 Potato Chip
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Ship the Chip
Tools and Accessories
 Scissors
 Marking
pen
 Pencils/Pens
 Calculator
 Rulers
 Clear
Adhesive
Tape
 Digital
Scale
 Masking Tape
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Ship the Chip
Scoring
Intactness _ Score
Overall _ Score 
Weight _ in _ Kg  Volume _ in _ cm3
Intactness score :

100: like new, perfect

50 : slightly damaged; cracked but still in one piece

25 : broken in 2 - 5 pieces

5 : broken in 6-20 pieces

1 : broken into more than 20 pieces; crumbled
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Ship the Chip
Calculating Volume

We will imbed the package in the smallest-volume
rectangular prism that contains it

We will calculate the volume of the prism;


Width x Length x Height

For example : 3cm x 4cm x12cm =144 cm3 in the prism shown
below
If your package weighed 100g and had a volume of 800 cm3
and the chip has arrived broken in 3 pieces:
Overall _ Score 
Intactness _ Score
Weight _ in _ Kg  Volume _ in _ cm3
25
Overall _ Score 
 0.3125
0.1 800
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Ship the Chip
Procedure
Sketch a design on the worksheet
1.

Label your worksheet with Table # and Team Name
2.
Construct a model of your package
3.
At a test station, drop the package from a height of 1.5
meters
4.
Open your package and examine the chip
5.
Calculate and record your score
6.
Using a second kit, redesign and construct a new package

Record the second design on the worksheet
7.
Label your package with Table # and Team Name
8.
Submit your worksheet and package to the Test Team for
overnight testing
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Exercise 2:
Sort It Out!
The engineering behind
industrial sorting
processes
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Safety First!!
 This
experiment uses scissors and box
cutters!
 Please
be slow, concentrated, and
careful when using them
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Sort It Out
Objectives


Learn about engineering of systems
and about measurements
Learn about sorting mechanisms
Get
an introduction to Performance
Indices and measures of errors

Learn about teamwork and cooperation
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Sort It Out
Sorting through History
 Miners
panning for gold
 Quality
control in food and other
industries
 Bottle
sorting for recycling
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Sort It Out
Different Types of Sorting
 Image
Processing for the
operation of Casinos:
 Off-the-shelf cameras, frame
grabbers, and image-processing
software used to develop a
Lighting
casino-coin sorting
system
Frame
Grabber
Digital I/O &
Network
Connection
Camera &
Optics
PC
platform
Inspection
software
Part Sensor
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Sort It Out
Different Types of Sorting
 Material
Properties of Coin:
 Current run through left
coil, creates magnetic field
 Magnetic field passes
through and is attenuated
by coin
 Right coil receives
magnetic field, creates
measurable current with
different value depending
on the coin
Coin in
Center
Transverse line
represents direction
of magnetic field
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Sort It Out
Why Coin Sorting is Needed
 Mixed
coins come from a
variety of sources and must
be sorted out before they
can be redistributed
 Coins from vending machines
 Coins from parking meters
 Also
helpful to identify fake or
foreign coins
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Sort It Out
Why Coin Sorting is Needed
 Mixed
coins are
 Sorted
 Rolled
 Re-circulated
through banks and
businesses
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Sort It Out
Your Turn

Groups of 2

You are a team of engineers hired
by a bank to develop a machine to
sort coins that are brought in by
customers.

Must mechanically sort 16 mixed
coins into separate containers.

In our experiment we use
washers:
 ½ Inch
 1 Inch
You will make TWO
 1¼ Inch
designs today
 1½ Inch
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Sort It Out!
Parallel Sorter
Input
Sorting
Mechanism
½”
1”
1½”
1¼”
Output
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Sort It Out!
Parallel Sorter
Input
Sorting
Mechanism
Output
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Sort It Out!
Serial Sorter
Input
Sorting
Mechanism
Output
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Sort It Out
Performance Index 1: “Distance Index”
How good is it?
 1: “Distance” performance
½ ½
½½
1 ½in
½
1
1
1 1
1in
1
index:
1¼1¼ 1¼
1¼
1¼
1¼in
1
1½
1½
1½
1½
1½in
Distance from correct bin
here, Derror = 2 bins
A
washer that does not get sorted has maximum
Derror = 3
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Sort It Out
Performance Index 2: “Percentage Index”
How good is it?

2: “Percentage” performance index:
½ ½
½½
1 ½in
½
1
1
1 1
1
1¼1¼ 1¼
1¼
1¼
1in
1¼in
1
1½
1½
1½
1½
1½in
# of washers incorrectly identified
Total # of washers to sort
40
5%
Sort It Out!
Table Number:
Type of Sorter
Team Name:
Serial
Parallel
Total washers sorted:
# of this type in
Container for this size washer:
each container
1/2"
1/2":
1":
1"
1 1/4"
16
1 1/2"
Number left unsorted:
Distance Index:
1 1/4":
1 1/2":
Percentage Index:
Sort It Out!
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Table Number:
Type of Sorter
The Perfect Group
Team Name:
Serial
Parallel
Total washers sorted:
# of this type in
Container for this size washer:
each container
1/2"
1/2":
1":
1 1/4":
1 1/2":
1"
1 1/4"
16
1 1/2"
4
Number left unsorted:
4
Distance Index:
0
0
4
4
Percentage Index:
0%
Sort It Out!
 Distance
Performance Index
 sqrt(
0x12 + 0x22 + 0x32 ) = 0
 A Perfect Score!

Remember: Lower is better
 Percentage
(
Performance Index
0 / 16 ) x 100 = 0%
 Another Perfect Score!
Sort It Out!
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Table Number:
Type of Sorter
Not That Perfect
Team Name:
Serial
Parallel
Total washers sorted:
# of this type in
Container for this size washer:
each container
1/2"
1/2":
1":
1 1/4":
1 1/2":
1"
1 1/4"
16
1 1/2"
4
Number left unsorted:
4
Distance Index:
0
1
4
1
3
Percentage Index:
6.25%
Sort It Out!
 Distance
Performance Index
 sqrt(
1x12 + 0x22 + 0x32 ) = 1
 A Less Than Perfect Score!

Remember: Lower is better
 Percentage
(
Performance Index
1 / 16 ) x 100 = 6.25%
 A Less Than Perfect Score!
Sort It Out!
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Table Number:
Type of Sorter
Serial
The Truly Miserable
Team Name:
Parallel
Total washers sorted:
# of this type in
Container for this size washer:
each container
1/2"
1"
1 1/4"
1 1/2"
1
1
1
1
1/2":
4
1":
1 1/4":
1 1/2":
16
Number left unsorted:
Distance Index:
2
6.16
4
2
Percentage Index:
56%
Sort It Out!
1/2":
1
1
Number left unsorted:
Distance
Index:
6.16
Percentage
Index:
2
56%
Performance Index
 sqrt(
1x12 + 1x22 + 4x22 + 1x32 + 2x32) = 6.16
 Much higher score, much lower performance

Remember: Lower is better
 Percentage
(
2
4
1 1/2":
 Distance
1
4
1":
1 1/4":
1
Performance Index
9 / 16 ) x 100 = 56.25%
 Again, much lower performance
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Sort It Out
Your Turn



Mechanical “shaking” of your device
is allowed as part of its operation
Design (draw) a mechanical
sorter that can separate the
½in, 1in, 1¼in, 1½in washers
Input: either
 Parallel – all 16 washers
are inserted at start of your
sorter together; or
 Serial – 16 washers are
inserted at start of your
sorter one at a time
Output: Each size of washer
in its own physical container
or surface

Materials:

glue, tape, paper or plastic
plates, cardboard, scissors
or hole punch, foil, paper,
cardboard tubes

washers
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Sort It Out
Your Turn

You will have 45 seconds to allow your sorter to operate

Predict the value of the two performance indices for your
design

Construct your sorting mechanism

Test it!

Can you do better?
You will make TWO designs today:
one PARALLEL and one SERIAL
Mechanical “shaking” of your device
is allowed as part of its operation
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Sort It Out
Conclusion
 Did
your sorting mechanism work? If not, why did
it fail?
 What
were your performance index values?
 What
levels of error would be acceptable in:


Medical Equipment manufacturing?
Nail manufacturing?
 What
redesigns were necessary when you went to
construct your design? Why?
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Exercise 3:
Pulleys &
Force
All about force and how
pulleys can help reduce it
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Pulleys & Force
Objectives
 Learn
about pulleys and pulley systems
 Learn
how using multiple pulleys can
dramatically reduce required force
 Learn
how pulley systems are used in
machines and impact everyday life
 Learn
about teamwork and problem solving
in groups
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Pulleys & Force
Basics of Pulleys: Two orientations
Fixed Pulley
Movable Pulley
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Pulleys & Force

The tension in the rope, T,
is always the same
everywhere

Fixed pulley allows for
change in direction of
applied force

Sum of the forces: vertically
Basics of Pulleys
Compound Pulley
2 T = 100 N
T = 50 N
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Pulleys & Force
Mechanical Advantage

Mechanical Advantage (MA) is
the factor by which a mechanism
multiplies the force or torque put into
it.

Ideal MA:

Actual MA:
This movable
pulley system
has a
mechanical
advantage of 2
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Pulleys & Force
Work

Work is the amount of energy
transferred by a force acting
through a distance

Work = Force x Distance
Work =
Force
x Distance

A bigger mechanical advantage
decreases the force required, but
increases the distance over which it
must be applied

The total amount of work required to
move the load stays the same
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Pulleys & Force
Efficiency
 The
ratio between Actual and Ideal
mechanical advantage is Efficiency
 Frictionless
system = 100% Efficiency
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Pulleys & Force
Pulleys in the World

Pulleys have long been used on
sailing ships to handle the rigging
and move the sails

Even with large mechanical
advantages, it still takes many people
to do the work!
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Pulleys & Force
Pulleys in the World

Pulleys are used in elevators
to change the direction of the
tension in the cable, reduce
power required of lift motor
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Pulleys & Force
Pulleys in the World

Industrial cranes lift large loads for
construction and transportation
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Pulleys & Force
Measuring Tension

Spring Scale

Calibrate: Hold spring scale at
eye-level and turn adjustment
screw until the internal indicator
is precisely aligned with the top
zero line

Measure: Create a loop in the
end of the rope you want to
measure tension in; attach
spring scale to loop. Hold the
spring scale steady and read off
the tension measurement.
+ Pulleys & Force
Your Turn

Groups of 2

Develop 2 systems to lift a filled soda bottle 10cm with

1 pulley

2 pulleys

Build your systems

Measure the distance the soda bottle moves and compare
it to the distance you had to pull


Measure the force you must exert on the string and
compare it to the force that is finally transmitted to the
soda bottle


What is the actual mechanical advantage?
What is the ideal mechanical advantage?
Calculate the efficiency of each system
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Pulleys & Force
Your Turn
 Now
join with one other group
at your table
 Develop
2 different systems to
lift a filled soda bottle 10cm
with all 4 pulleys
 Build
both systems
 What
are their actual
mechanical advantages? Ideal?
 Which
one has a better
efficiency? Why do think that
is?
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Pulleys & Force
Conclusion

Which system required the least amount of force to lift
the bottle? How did this system rank in its mechanical
advantage?

Do you think the size of the pulley makes a difference in
the ideal mechanical advantage? Actual?

How could you further increase the efficiency of your
most efficient pulley system design?

What other engineering problems were solved with
pulleys or pulley systems?
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Spring Scale

www.arborsci.com
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End of Saturday Exercises
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TISP: Uruguay
Sunday, 10 May 2009
54
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Exercise 4:
Critical
Load
Structural engineering
and how to reinforce the
design of a structure to
hold more weight.
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56
Critical Load
Objectives
 Learn
about civil engineering and the
testing of building structure
 Learn
about efficiency ratings and critical
load
 Learn
about teamwork and the engineering
problem solving
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Critical Load
Great Structures of the World
Millau Viaduct

Millau, France

World’s Tallest Bridge

2460m long
434m pylon height
270m road height

December, 2004
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Critical Load
Great Structures of the World
Yokohama Landmark Tower

Yokohama, Japan

Japan’s Tallest
Office Building

296m tall
70 floors including office
and hotel

July, 1993
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Critical Load
Great Structures of the World
Beijing National Stadium – “Bird’s
Nest”




110,000 tons of steel used
in construction

3,000,000 cubic meters

Opened June, 2008
World’s Largest Steel Structure
258,000 square meters
5 years to construct
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Critical Load
Great Structures of the World
Crystal Cathedral

Garden Grove,
California, USA

World’s Largest
Glass Building

12 stories tall
12,000+ panes of
glass

16,000-pipe organ

Opened 1980
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Critical Load
Great Card Structures of the World
Skyscraper of Cards
 2007 World
Record
House of Cards
 Over
7.5 meters tall
 No
glue or tape; just
cards
 Built
2007
by Bryan Berg in
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Bryan Berg at Work
A “cardstacker” from Santa Fe, NM, USA
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Critical Load
What is Critical Load?
 Force
is placed on a
structure
Force
 Structure
can support up to
a certain force created by
the weight
 At
a certain point, the
structure will fail,
breaking
 The
maximum force the
structure can sustain
before failure is known
as the “Critical Load”
Force
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Critical Load
Efficiency
A
high critical load is not the only parameter to
consider

Is the best bridge made by filling a canyon with concrete?
It certainly would have a high critical load!
 Consider

also the weight of the structure
Lighter is better, given the same critical load
 These
two parameters are combined in an
“Efficiency Rating”:
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65
Critical Load
Your Turn

Groups of 2

Up to 12 cards + 1m tape

Devise a plan to build a load bearing
structure
 Should have a flat top
 Support load with base area of
10x10cm at least 8 cm above the
table

No altering of cards allowed – just
tape!

No wrap-ups of tape
 Tape is used to connect cards only
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FREQUENTLY ASKED QUESTIONS
 STRUCTURE NEEDS TO BE CONNECTED
 BENDING
OF CARDS IS ALLOWED
 CUTTING
OF CARDS IS NOT ALLWOED
 YOU
CAN ATTACH SEVERAL CARDS
TOGETHER TO MAKE A THICKER CARD
 THE TOP
OF THE STRUCTURE SHOULD ALLOW
FOR A LOAD WITH 10X10CM BASE
 HEIGHT
SHOULD BE AT LEAST 8CM
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67
Critical Load
Your Turn
 Example:
 Supports
load
 Load is at least 8cm above
table
 Cards failed after load of
2.4kg
 Structure made with 4
cards
 Efficiency rating:
2.4 kg / 4 cards = 0.6
kg/card
8.5 cm
height
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68
Critical Load
Your Turn
 Your
efficiency rating:
[Load at Failure] / [# of cards used]
 Predict
 Build
 Test
what the rating of your design will be
your design
it!
 Discuss
improvements, then repeat exercise for
a second design
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69
Critical Load
Conclusion
 What
was your efficiency rating?
How close were you to your prediction?
 How
was your design different from the best
design?
 How
would you change your design? Why?
 What
other factors would you need to take into
consideration if your Card House were a real
office building?
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End of Sunday Exercises
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